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Abstract:

Highly flexible finished wood laminate, formed by several substrates that
include a transparent plastic film finish, a layer of pre-varnished
sanded wood, a plastic film with corona treatment on both faces and a
flexible substrate. It is easy to affix using glue on straight and shaped
surfaces and even adapts to acute corners without cracking; manufacturing
process for the laminate.

Claims:

1. Highly flexible finished wood laminate comprising several substrates,
which is easy to affix on straight and shaped surfaces and adapts to
acute corners without cracking, with the substrates set out in following
order: (i) varnished sanded wood veneer; (ii) plastic film with corona
treatment on both faces; and (iii) flexible substrate.

2-3. (canceled)

4. Highly flexible wood laminate, as described in claim 1 with a
polyethylene plastic film with corona treatment on both faces.

5-7. (canceled)

8. Highly flexible wood laminate, as described in claim 1, which has a
transparent plastic film finish affixed to the varnished veneer.

9-10. (canceled)

11. Highly flexible wood laminate, as described in claim 8, with a
polypropylene transparent plastic film finish.

12-13. (canceled)

14. Highly flexible wood laminate, as described in claim 1, with a metal
laminate affixed using a flexible glue beneath the flexible substrate
which supports the veneer.

15-42. (canceled)

43. Highly flexible wood laminate, as described in claim 1, with a
textile flexible substrate.

44. Highly flexible wood laminate, as described in claim 1, with a paper
flexible substrate.

45. Highly flexible wood laminate, as described in claim 8, with a
transparent plastic film finish affixed to the varnished veneer by means
of corona treatment, pressure and heat.

46. A manufacturing process for highly flexible finished wood laminate,
said process comprising: affixing a wood veneer onto a flexible substrate
using polyethylene with corona treatment on both faces, applying pressure
and heat, and forming a roll; sanding the wood veneer roll; and
varnishing the wood veneer roll.

47. The manufacturing process of claim 46 further comprising: affixing a
plastic film finish to the varnished wood veneer using pressure and heat.

48. The manufacturing process of claim 47 further comprising: affixing
the highly flexible finished wood laminate to a metal laminate using a
polyethylene film with corona treatment on both faces, laminated between
both substrates, applying pressure and heat.

49. The manufacturing process of claim 47 further comprising: affixing
the highly flexible finished wood laminate to a metal laminate using
flexible glue.

Description:

BRIEF

[0001] Finished wood laminate with a high flexibility in the direction of
the grain, formed by several substrates, which is easy to affix using
glue on straight and shaped surfaces and even adapts to acute corners
without cracking, for finishing walls, furniture, coverings, door faces,
wood moldings and many other wood-finish products, flat or with curves,
corners, radiuses or as indicated in the design and in the direction of
the grain. Can also be affixed to a metal support such as aluminum,
zincalume or galvanized iron, which is subsequently bent into different
shapes in the direction of the grain of the wood which, due to its high
flexibility, is resistant to cracking. This allows for a wide range of
wood-finish profiles to be created, forming linear color coverings and
ceilings that have so far been widely used in public spaces such as
airports and shopping malls.

[0002] Wood laminate is a very well known use of wood for finishing
furniture, doors and wall coverings. In other words, the parts to be used
are cut to the size of the furniture or covering from a low-cost material
such as particle board, medium-density fiberboard (MDF), plywood, etc.
and layered with a thin wood laminate called a veneer. This process
consists of applying a cold glue to the substrate, placing the wood
veneer on top and applying pressure. Direct wall covering, which is less
used given its high level of complexity and costs, involves an artisanal
process in which contact adhesives are used to affix the veneer to the
wall, which is then sanded and varnished.

[0003] An alternative way of working with flexible finished wood laminate
is by affixing the veneer to a highly flexible substrate (fabric used to
be commonly used), sanding it to thin it and give it flexibility and then
applying a varnish. These processes can be used to create bendable
coverings for corners of walls, but they also create a weak point in the
product as it undergoes a controlled fracture, leaving small cracked
splinters which can become unstuck, ultimately affecting the durability
of the covering. This is because a consistent application of varnish
cannot be guaranteed among the wood fibers. This process is also
difficult and expensive.

[0004] The invention is a highly flexible finished wood laminate, formed
by several substrates arranged in the following order: a transparent
plastic film finish, a sanded and pre-varnished veneer, a plastic film
with corona treatment on both faces and a flexible support. The
transparent plastic film may be made from polypropylene, polyethylene,
PVC or polyester. The flexible support may consist of cellulose and
synthetic papers. Its composition is determined by the glue used to apply
the laminate to the product to be covered. The first process in
manufacturing this highly flexible finished wood laminate is to affix the
veneer to a flexible substrate using a plastic film with corona treatment
on both faces, which is laminated with heat and temperature between both
elements. The wood face of the veneer is then sanded and pre-varnished,
giving firmness to the substrate affixed to the veneer using the plastic
film. Since both the flexible support and the plastic film with corona
treatment on both faces are wound into rolls, the wood face of the veneer
can be continuously sanded and pre-varnished. Once this level of finish
is reached, i.e. sanding and pre-varnishing, a transparent plastic film
finish is applied, which binds the wood fibers together to give them
continuity, resulting in a high level of flexibility in the direction of
the grain. This transparent plastic film finish is affixed using a glue
which is pre-applied to the film or using a corona treatment on the film,
in both cases on the face which is affixed to the pre-varnished side,
which is then laminated by rolls applying heat and pressure. This
transforms the product from a wood veneer into a very thin laminate with
a wood veneer interior, providing its aesthetic quality, while the other
components give it its flexibility in the direction of the grain. In some
cases, one or more affixing processes may be applied using a flexible
glue, which does not affect the overall flexibility of the product. The
process of affixing the highly flexible finished wood laminate to a metal
laminate may also be carried out using a flexible glue, capable of
withstanding the subsequent bending process.

[0005] The flexible finished wood laminate can be used in a wide range of
products for covering walls, molding and for general fine wood finishes.
The final use of the product depends on the properties of the film
applied after pre-varnishing and on the pre-varnishing itself. The
product can be used as a primer for furniture and coverings and, once
mounted, the finish layer is affixed using a contact glue or cold glue.
When applied to a wall, the type of glue used must be carefully selected.
For water-based glues such as wallpaper pastes, the wall must allow for
humidity to escape since manufacturing processes can leave laminates
impermeable to water both on the front and back faces. A self-adhesive
glue may be applied to the back of the flexible laminate, with the
corresponding silicon paper, with which it may be affixed to any
substrate such as an impermeable wall, glass, varnished wood, etc. and
which transform the laminate into a product that anyone can install at
home.